Residue Management Improvement Parts Catalog

Transcription

1 Farmer Invented. Farmer Tested. Farmer Proven. TM Residue Management Improvement Parts Catalog Call Today for Pricing & Special Discounts! Case-IH* 3000 AGCO* John Deere* New Holland* 96c/98c/ 98d/996 Geringhoff* NorthStar Case-IH* 2200/ 2400 CalmerCornHeads.com (309) Disclaimer: * Trademarks are not owned by, affiliated with, or under license to Calmer Corn Heads, Inc. and are used solely for truthful advertising for the utility of Calmer Corn Head products advertised herein.

2 Top Reasons to Buy Calmer BT Chopper Stalk Rolls and Upgrade Kits Reason # 1: John Deere Tested In 2015, John Deere & Co. tested their stalk rolls against the BT Chopper Stalk Rolls and another aftermarket stalk roll design. Their tests supported what we ve been saying all along. Smallest Residue Sizing < 2 > 6 > 6 > 6 Calmer BT Choppers John Deere Intermeshing 6 Flutes John Deere 8 Opposing Flutes 360 Yield Chainroll Intermeshing 8 Flutes Calmer BT Choppers = < 2 in length OEM Stalk Rolls = > 6 in length Lowest Gear Box Spreader Load % 100% 124% 157% Minimal Horsepower Increase 106% 100% 104% 128% Calmer BT Choppers John Deere Intermeshing 6 Flutes John Deere 8 Opposing Flutes 360 Yield Chainroll Intermeshing 8 Flutes Calmer BT Choppers John Deere Intermeshing 6 Flutes John Deere 8 Opposing Flutes 360 Yield Chainroll Intermeshing 8 Flutes Source: Data published by Deere & Company. YouTube, under the name John Deere 600C Stalk Roll Advantage. *Disclaimer: Trademarks are not owned by, affiliated with, or under license to Calmer Corn Heads, Inc. and are used solely for truthful advertising for the utility of Calmer Corn Head products advertised herein. Reason # 2: Endorsed on NewAgTalk.com NewAgTalk.com continues to be a trusted medium for farmers to openly exchange ideas and reviews on ag products. Over the years, discussions surrounding Calmer products have attracted more than a million views. Below are some past Calmer-related discussions important to farmers. 1 1 Are Calmer Corn Head Products worth the money? Posted 12/3/2013 An overwhelming majority of respondents said yes Calmer stalk rolls vs. Geringhoff Rota Disc Posted 10/16/2016 An overwhelming majority of respondent preferred Calmer BT Choppers over the Geringhoff Rota Disc Satisfied with the longevity of Calmer BT Choppers? Posted under Calmer s Kit on 10/27/2016 An overwhelming majority of respondents were satisfied with the longevity of Calmer BT Choppers Overall satisfaction with Calmer products An overwhelming majority of respondents were/are satisfied with Calmer products

3 Reason # 3: University Proven In 2016, The University of Illinois Department of Crop Sciences found that Calmer BT Chopper Stalk Rolls increase continuous corn yields by an average of 6 bu per acre when compared to OEM stalk rolls. A B C D Mechanical residue management in corn on corn the previous fall (A and B) and at the R3 growth stage the following season (C and D): Standard stalk rolls (A and C) and Calmer BT Choppers (B and D). 45% degradation Standard Stalk Rolls Residue Degradation % 216 bu/ac Standard Stalk Rolls 52% degradation Calmer BT Choppers 222 bu/ac Calmer BT Choppers % Emergence Corn on Corn BT Chopper Stalk Rolls Corn on Corn Standard Stalk Rolls Day of Emergence Conclusion Data compliments of Alison Vogel, Tryston Beyrer and Dr. Fred Below University of Illinois at Urbana-Champaign Reason # 4: Mechanical and Agronomic Advantages With numerous mechanical and agronomic advantages, you re getting more than just corn head parts, you re getting a peace of mind that your residue management problems are solved for good during harvest. Mechanical Advantages: 25% Less Hp Needed than with Chopping Heads Superior Cornstalk Engagement Agronomic Advantages: Unmatched Residue Decomposition Easier Planting Compatible with all Tillage Systems Warmer Soils Better Ear Separation Less Tire Wear Less Butt Shelling Drier Soils Increased Earthworm Populations Reduced Nitrogen Penalty Higher Yields Slower Head Speeds Lasts Longer than OEM Components Easier on Gearboxes Increased Harvesting Speeds Reason # 5: Award Winning. Farmer Invented. Farmer Tested. Farmer Proven. Our products are farmer invented, farmer tested, and farmer proven and come with a 100% Satisfaction or Your Money Back Guarantee. Having been voted to the No-Till Product of the Year list five times, farmers across North America continue to rely on our award-winning technology to solve their residue management and corn head problems. 2

4 JD 40/90 Series Corn Heads Follow Calmer s 3-step upgrade process to solve many of your corn head and residue management problems. STEP 1 Install Calmer BT Chopper Stalk Rolls and Weed Knives Reliable and effective stalk rolls are critical to a top-performing corn head. Calmer s BT Chopper Stalk Rolls have a redesigned nose cone and a patented open window design in the front to guarantee 100% traction of stalks and superior feeding in both standing and down corn. The 10 razor sharp knives on each roll cut, chop and shear cornstalks into confetti-like pieces for accelerated decomposition. As a result, you ll be able to more effectively manage residue during tillage and planting. Calmer Weed Knives are specially designed to match the curvature of the BT Choppers redesigned nose cones and prevent the back wrapping of grasses. STEP 2 Install Calmer Gathering Chain Slow Down Kit By slowing down gathering chains by 25% with Calmer s smaller 6-Tooth Drive Sprockets, trash intake can be reduced by as much as 60%. The larger 9-Tooth Idler Sprockets improve the chains grabbing ability for easier harvesting in down corn conditions. This new-and-improved, non-greaseable idler sprocket is solid steel and has a replaceable bearing for increased life and lower maintenance. Longer-lasting Chrome-Pin Gathering Chains are sent with all Slow Down Kits. STEP 3 Install Calmer Multi-Zone Beveled Stripper Plates The contour of the Calmer Multi-Zone Beveled Stripper Plates emulates the butt of the corn ear, which helps reduce butt shelling while simultaneously reducing trash intake by allowing husks and leaves to pass through the stripper plate gap onto the ground, not into the combine. Calmer s Over-Sized Plastic Gathering Chain Paddles can be installed on the gathering chain lugs to improve both the gathering and conveying performance of material. 3 JD 40/90 Series

5 JD 40/90 Series Weed Knives We are really pleased with Calmer s Trash Reduction Row-Unit Upgrade Kit. The kit took care of every problem we had. We installed it last season and it was the first season we had without stopping once to remove trash from the corn head. We wish we had installed it years ago. Roger Groton SOUTH DAKOTA 9-Tooth Idler Sprockets Chrome-Pin 48 Pitch Gathering Chains 6-Tooth Drive Sprockets With Calmer s Trash Reduction Kits, harvesting in frozen fields was no problem. The stalks splinter and shatter in both directions. There were no problems with dozing at the end of the fields, and the down corn was easy to pick. No popping ears! We should have upgraded our 893 sooner! Jon Vosburg LEWISTOWN, IL Manual Adjust Multi-Zone Beveled Stripper Plates Hydraulic Adjust Multi-Zone Beveled Stripper Plates JD 40/90 Series 4

6 Cornstalks Still Standing After Harvest PROBLEM No Feeding Chamber Without a feeding chamber, overlapping flutes on OEM stalk rolls spinning at approx. 950 RPMs create a wall of rotating steel and restrict the entry of the cornstalk. By examining the used 6-fluted stalk roll below, it is evident the first 2-inches of flutes are worn, while the remainder of the flutes remain in good condition. worn spiral First 2 inches of flutes are worn out Remaining 14-inches are in like new condition Steel Flutes Block Entry NO Entry Window 6-fluted knife rolls after 250 row acres The Evidence Intermeshing stalk rolls with 6 flutes have a continuous overlap in the entry area. When rotating at normal speeds, these intermeshing flutes prevent cornstalks from engaging easily with the flutes. This hesitation results in stalks and ears passing below the corn head without being processed. This makes the field look like it was plucked, not picked. (See photo on the left) The Results To demonstrate, we put a cornstalk in front of an OEM stalk roll s knife chamber. Because it does not have a revolving open window, the cornstalk cannot engage with the flutes and ultimately bends over. (See photo below) Cornstalks CANNOT travel easily into knife chamber. No Stalk Engagement 5 JD 40/90 Series

7 JD 40/90 Series Calmer s Patented Open Window Creates A Feeding Chamber SOLUTION Install Calmer s Patented BT Chopper Stalk Rolls 10 razor sharp knives process stalks Open Window Patented Open Window During rotation, the shortened flutes are timed to create 2, 4-inch open windows for superior stalk engagement. The Evidence Calmer s patented open window allows the cornstalks to feed easily from the spiral area into the 17 1/2-inch knife chamber, which allows for the entire cornstalk to be processed. This makes for longer stalk roll life and reduces low ear snap and the bulldozing of stalks at the end rows. Because this open window guarantees 100% traction the first time a blade touches the stalk, this ultimately means increased profits for you! The Results To demonstrate, we put a cornstalk in front of the Calmer BT Chopper Stalk Roll. Because of its patented open window, the stalk stays vertical and is easily received and engaged ed by its 10 razor sharp blades. Cornstalks CAN travel easily into this roll with an open window. Calmer BT Choppers explode stalk stubs for quicker residue decomposition and less tire wear! JD 40/90 Series 6

8 Long, Unprocessed Stalks Are Slow to Decompose PROBLEM Non-Agressive Flutes Result in Long Stalks That Limit Residue to Soil Contact Cornstalks did not travel into the knife chamber. Tall stalks left in the field will be slow to decompose. Residue from factory rolls is hard to plant into. Calmer BT Chopper residue is easier to plant into. Knife-to-Knife Stalk Rolls = 92% residue cover on 06/25/2014 Calmer BT Chopper Stalk Rolls = 78% residue cover on 06/25/ JD 40/90 Series

9 JD 40/90 Series 10 Intermeshing, Razor-Sharp Flutes Cut, Chop and Shear Cornstalks into Confetti for Residue-to-Soil Contact Install Calmer s Patented BT Chopper Stalk Rolls When harvesting, the upper pair of knives on the BT Choppers maintain grasp and control of stalks (Zone A below). This prevents the upper portion of stalks from becoming disengaged and eventually going in the combine. The center pair of knives cut, chop and shear cornstalks into confetti-like residue for accelerated decomposition, eliminating the need for chopping stalks or chopping corn heads. (Zone B below) SOLUTION Never chop stalks again! Cut, Chop and Shearing Area Less Blowing of Leaves and Husks The cornstalk stubble left by BT Choppers serves as form of snow fence by preventing the blowing of leaves and husks on windy days. Confetti-like residue stays in place and is less likely to blow. Zone-A Zone-B Note: The spirals and open windows have been removed. Zone A: Knives maintain grasp and control of the stalk. Zone B: Intermeshing knives chop, cut and shear. BT Choppers achieve instant residue-to-soil contact by chopping and shearing cornstalks into small pieces, while simultaneously exposing the pitch for accelerated residue decomposition. JD 40/90 Series 8

10 Large Pile of Fluff on Dry Afternoon PROBLEM Excessive Gathering Chain Speed With the introduction of BT Corn genetics, today s corn hybrids are taller, drier and more brittle during harvest time. Prior to 2008, these corn heads utilized row units with speed ratios from the 1960s that used fast gathering chain speeds. This often results in the gathering chain lugs shearing off the top of the corn plant before the rolls have a chance to pull stalks below the stripper plates. These broken portions of the corn plants then end-up in the cross auger, eventually resulting in the build-up of a large pile of fluff. (See photo below) The Evidence The first indication that the gathering chains were running too fast was confirmed during kill stops. Examinations of the large pile of fluff indicated it was composed mostly of the top portion of the corn plant that was sheared-off by the gathering chain lugs. (See photo below) The second indication was cornstalks hair-pinning at the top of the stripping tunnel on a wet or damp day. This happens because the gathering chain lugs force the top portion of the corn plants over the row frame unit. Kill Stop Examination Photo provided by Eric Hayenga. (Taken in Groton, SD - November, 2000) Top half of plant 9 JD 40/90 Series

11 JD 40/90 Series Slow Down Gathering Chain Speed By 25% Install Calmer s Slow Down Kit Calmer s Slow Down Kit consists of 6-tooth drive sprockets, 9-tooth idler sprocket and chrome-pin gathering chains. Install Calmer s 6-Tooth Drive Sprockets to slow down gathering chain speeds by 25%, reduce trash intake by an average of 60% and 100% eliminate the build-up of large piles of fluff. This smaller drive sprocket allows the stalk rolls to make additional revolutions, allowing for the full plant to be processed before the gathering chain lugs can break it off. Install Calmer s 9-Tooth Idler Sprockets for the following reasons: 1. They reduce the slack created by the 6-tooth drive sprocket, so a standard 48 pitch gathering chain can be used. New chrome-pin chains are sent with all orders of the Calmer Slow Down Kit for increased life. 2. The bigger diameter reduces wear on the idler block. 3. The bigger diameter increases the gathering chain lug s grabbing ability in down corn. 4. Non-greaseable, solid-steel design has a replaceable bearing for increased wear life and lower maintenance. The Results We converted half of our test corn head with Calmer s 6-Tooth Drive Sprockets, leaving the other half with the factory 8-tooth sprockets. We did multiple kill stops at normal ground speeds, bagged the loose trash on both halves, weighed it and compared the difference. The reduction of trash intake was visible from the combine and confirmed by the test data below. SOLUTION 6-Tooth Drive Sprocket Chrome-Pin 48 Pitch Gathering Chain 9-Tooth Idler Sprocket Time 1:45 2:00 5:00 5:30 TOTAL Ounces of Trash with 6-Tooth Ounces of Trash with 8-Tooth Ounces of Trash Reduced Total Trash Reduced 54% 78% 53% 60% 60% Average During multiple kill stops on a dry afternoon, the Calmer 6-Tooth Sprockets reduced trash intake and stalk breakage by as much as 78% in 15% moisture corn. Harvesting speeds increased from 3 to 6 mph. Marion Calmer JD 40/90 Series 10

12 High Leaf Intake, Butt Shelling, and Unhusked Ears PROBLEM Straight Stripper Plates Factory straight stripper plates are not formed to match the natural shape of the bottom side of the corn ear. During ear separation, the plant leaves engage with these straight stripper plates, causing them to be unnecessarily torn from the stalk. Because factory straight stripper plates do not emulate the rounded butt of the corn ear, they do not allow the ear shank to get close enough to the stalk rolls to grasp the ear shank. This results in the husk staying attached to the ear, sending it and more material into the combine. The Evidence Cornstalk leaves and ear husks are mixed-in with yellow ears during the kill stop examinations. (See photo below on right) The cornstalk leaves and ear husks are mixed in with yellow ears during kill stop examinations. Factory straight stripper plates increase butt shelling. Too much yellow (leaves, husks and stalks) out of the straw chipper is evidence of high trash intake and that the corn head is picking dirty. 11 JD 40/90 Series

13 JD 40/90 Series Multi-Zone Beveled Stripper Plates SOLUTION Install Calmer s Multi-Zone Beveled Stripper Plates These multi-zone beveled stripper plates are straight in the front retrieving area to reduce ear wedging and beveled in the stripping area to allow the stalk rolls to engage more shanks, husks and leaves, reducing trash intake by an average of 33%. The beveled edge also emulates the rounded bottom of the corn ear to help reduce butt shelling issues. These beveled stripper plates are hard surfaced for extended life. The Results We installed Calmer s Multi-Zone Beveled Stripper Plates on half of our test head, while the other half remained equipped with factory straight stripper plates. The stripper plate gaps were set the same on both sides of the corn head during testing. We did multiple kill stops at normal ground speeds on a dry afternoon, bagged any loose trash on both sides, weighed it and compared the difference. Here were our findings: On the side of the corn head equipped with Calmer s multi-zone beveled stripper plates, trash was reduced by an average of 33% Harvesting speeds increased significantly Calmer s Multi-Zone Beveled Stripper Plates emulate the rounded bottom of the corn ear. This does a better job of displacing the energy that causes butt shelling. I put Calmers on a 1290 and ran it side-by-side with a competition 18 row, 20-in corn head. There was no comparison. Calmer was so much better. Better feeding and better chopping! John Liniger SYCAMORE, OH Time 1:15 2:00 2:10 2:30 3:00 3:30 4:30 Ounces of Trash with Straight Stripper Ounces of Trash with Beveled Stripper Plates Ounces of Trash Reduced Percentage of Trash Reduced 40% 13% 0% 42% 40% 30% 36% 33% Average Calmer s beveled stripper plates push more kernels toward the cob, reducing butt shelling. JD 40/90 Series 12

14 Profitable Corn Head Adjustments and Modifications Feeder house reverser maintenance Only use full synthetic oil in the reverser. There are 2 grease fittings on the reverser. These need to be placed at the 12 o clock and 2 o clock positions. Put 12 pumps of grease in the 12 o clock and only 2 pumps of grease in the 2 o clock. Never over grease! Once you start the machine (at idle), run the variable speed up and down (2X) to lubricate prior to harvest. Oil bath settings The 40/90 corn head should have the oil bath in overdrive, the large sprocket on the back (driver), and the small sprocket on the front (driven). Please refer to the following 40/90 corn head gear ratios: Driver; 25 Driven Driver; 25 Driven Driver; 18 Driven Driver; 18 Driven Check lube level in gear boxes See manufacturer s owner s manual for proper lubricant specifications. Calibrating gathering chain speed To calibrate RPMs, all Calmer orders come with an orange colored paddle to bolt onto a center gathering chain lug. Raise the corn head, put combine in park, engage threshing motor to full speed. Count revolutions for 1 minute. Begin calibration with initial gathering chain speed of 55 RPMs. If butt shelling is a problem, slow down the corn head speed until it starts to bulldoze cornstalks, then speed back up until bulldozing stops. Bolt onto center gathering chain lug. Arrow points to where the red gathering chain lug should be bolted to the gathering chain. To reduce ear toss Stay on the fast sprocket for feeder chain speed when harvesting. Move cross auger back as close as possible to the feeder chain drum. Add half and/or full links to the feeder chain to extend toward the cross auger. This reduces the dead air space between the feeder chain and cross auger flighting. This also reduces the height of the pile of ears between the cross auger and the feeder house, along with reducing back feeding and ear toss. Some older John Deere corn heads use rubber flaps and no reverse flighting. The performance of these older augers is poor. It is recommended that you remove the rubber flaps. If necessary, add reverse flighting to the center of the auger. The short section of reverse flighting can be purchased from John Deere (RH part #H206301, LH part #H206302) and welded on. (See photo next page) 13 JD 40/90 Series

15 JD 40/90 Series Setting stripper plates Begin with normal settings of 1 1/8-inch gap at the front and 1 3/16-inch gap at the rear, then adjust accordingly to ensure plates are 1/16-inch wider than the diameter of the 3rd cornstalk node above the brace root. Ensure stripper plate gap is centered over the stalk rolls. Used gathering chain tighteners occasionally lock-up This is caused when the spring vibrates and augers itself into the hole between the bolt and the flat strap. This can be fixed by removing the idler bolt and adding a second washer (enclosed) at the bottom of the pipe spacer, which is identical to the washer at the top of the pipe spacer. Apply anti-seize or lubricant to the bolt threads for future adjustments. Corn head angle is very important! The angle of the corn head should be between degrees for optimum performance in standing corn. The angle should be set to 20 degrees in down/lodged corn. Flattening the angle to 20 degrees in down corn makes gravity less of an enemy. To set the corn head angle, put the combine on a level surface, then lower the corn head until the row unit frame is 2-inches off the ground. Place a magnetic protractor (included with all stalk roll and residue management kit purchases) on the stripper plate and read the angle. If the angle is too steep, pull the top of the corn head toward the combine or pushout the bottom with a wedge kit, or a combination of both. Sieve settings Marion s recommendations: In Corn: The bottom sieve is not needed. There is no part of the cob or kernel that needs to be re-threshed. Therefore, the bottom sieve should be wide open. This allows the kernels to fall directly into the clean auger. The bottom sieve is now functioning as a wind board and helps direct the air blast to the front of the top sieve where it is needed for cleaning. During corn harvest there should be nothing in the return elevator but the chain and paddle. I would suggest a couple of kill stops to confirm this. The top sieve is now the cleaning sieve and has plenty of capacity to perform this function without losing kernels out the back. I open and close the top sieve as kernel size and moisture change to remove 95% of the cobs from the grain tank. Sieve loss should be less than separator loss. Plastic gathering chain paddles attached to the gathering chain lugs will improve gathering and conveying performance in down corn. Adjust auger to 1 3/4-inches clearance between flighting and tray at the tightest point to reduce ear slicing. Also adjust rearward as far as possible. Use a protractor to achieve the correct corn head angle. Reverse flighting JD 40/90 Series 14

16 JD 600/700 Series Corn Heads Follow Calmer s 3-step upgrade process to solve many of your corn head and residue management problems. STEP 1 STEP 2 Install Calmer BT Chopper Stalk Rolls and Weed Knives Reliable and effective stalk rolls are critical to a top-performing corn head. Calmer s BT Chopper Stalk Rolls have a redesigned nose cone and a patented open window design in the front to guarantee 100% traction of stalks and superior feeding in both standing and down corn. The 10 razor sharp knives on each roll cut, chop and shear cornstalks into confetti-like pieces for accelerated decomposition. As a result, you ll be able to more effectively manage residue during tillage and planting. Calmer Weed Knives are specially designed to match the curvature of the BT Choppers redesigned nose cones and prevent the back wrapping of grasses. Calmer Weed Knives not available for chopping corn heads. Install Calmer Multi-Zone Beveled Stripper Plates The contour of the Calmer Multi-Zone Beveled Stripper Plates emulates the butt of the corn ear, which helps reduce butt shelling while simultaneously reducing trash intake by allowing husks and leaves to pass through the stripper plate gap onto the ground, not into the combine. STEP 3 Install Chrome-Pin Gathering Chains (600 Series Only) Chrome-Pin Gathering Chains are an available option with every upgrade kit. The chrome-pin design results in a longer-lasting, more durable chain. OEM Residue BT Chopper Residue Side-by-side comparison just 7 months after harvest shows superior residue decomposition when using Calmer BT Chopper stalk rolls compared to OEM stalk rolls. 15 JD 600/700 Series

17 JD 600/ 700 Series Weed Knives 600 old shaft has an X pattern 600 new shaft has a + pattern Multi-Zone Beveled Stripper Plates for Old Frame Design with 8-Tooth Sprocket System Multi-Zone Beveled Stripper Plates for New Frame Design with 6-Tooth Sprocket System Chrome-Pin Gathering Chains JD 600/700 Series 16

18 Cornstalks Still Standing After Harvest PROBLEM No Feeding Chamber Without a feeding chamber, overlapping flutes on OEM stalk rolls spinning at approx. 950 RPMs create a wall of rotating steel and restrict the entry of the cornstalk. By examining the used 8-fluted stalk roll below, it is evident the first 2-inches of flutes are worn, while the remainder of the flutes remain in good condition. No entry window results in early wear of the first 2-inches of knives and fails to utilize the remaining portion. Steel Flutes Block Entry NO Entry Window The Evidence Knife-to-knife stalk rolls with 8 flutes have continuous overlap in the entry area. When rotating at normal speeds, these intermeshing flutes prevent cornstalks from engaging easily with the flutes. This hesitation results in stalks and ears passing below the corn head without being processed. This makes the field look like it was plucked, not picked. (See photo on the left) The Results To demonstrate, we put a cornstalk in front of an OEM stalk roll s knife chamber. Because it does not have a revolving open window, the cornstalk cannot engage with the flutes and ultimately bends over. (See photo below) Cornstalks CANNOT travel easily into knife chamber. No Stalk Engagement 17 JD 600/700 Series

19 JD 600/ 700 Series Calmer s Patented Open Window Creates A Feeding Chamber SOLUTION Install Calmer s Patented BT Chopper Stalk Rolls 10 razor sharp knives process stalks Open Window Patented Open Window The Evidence Calmer s patented open window allows the cornstalks to feed easily from the spiral area into the 17 1/2-inch knife chamber, which allows for the entire cornstalk to be processed. This makes for longer stalk roll life and reduces low ear snap and the bulldozing of stalks at the end rows. Because this open window guarantees 100% traction the first time a blade touches the stalk, this ultimately means increased profits for you! The Results To demonstrate, we put a cornstalk in front of the Calmer BT Chopper Stalk Roll. Because of its patented open window, the stalk stays vertical and is easily received and engaged by its 10 razor sharp blades. Cornstalks CAN travel easily into this roll with an open window. During rotation, the shortened flutes are timed to create 2, 4-inch open windows for superior stalk engagement. Calmer BT Choppers explode stalk stubs for quicker residue decomposition and less tire wear! JD 600/700 Series 18

20 Long, Unprocessed Stalks Are Slow to Decompose PROBLEM Non-Agressive Flutes Result in Late Pull Factory Stalk Rolls Tall stalks left in the field will be slow to decompose. Factory stalk rolls are knife to knife and utilize a 1/8 to 1/4 air gap between blades. This gap is too wide which results in a slow or late pull of cornstalks, especially on a damp or rainy day. As a result, the amount of cornstalks consumed through the rolls is less than needed. This contributes to the gathering chain pushing and hair pinning the top portion of the stalk between the stripper plates and row frame, causing cornstalks to hairball. Residue from factory rolls is hard to plant into. Calmer BT Chopper residue is easier to plant into. Knife-to-Knife Stalk Rolls = 92% residue cover on 06/25/2014 Calmer BT Chopper Stalk Rolls = 78% residue cover on 06/25/ JD 600/700 Series

21 JD 600/ 700 Series 10 Intermeshing, Razor-Sharp Flutes Cut, Chop and Shear Cornstalks into Confetti for Residue-to-Soil Contact Install Calmer s Patented BT Chopper Stalk Rolls When harvesting, the upper pair of knives on the BT Choppers maintain grasp and control of stalks (Zone A below). This prevents the upper portion of stalks from becoming disengaged and eventually going in the combine. The center pair of knives cut, chop and shear cornstalks into confetti-like residue for accelerated decomposition, eliminating the need for chopping stalks or chopping corn heads. (Zone B below) SOLUTION Never chop stalks again! Cut, Chop and Shearing Area Less Blowing of Leaves and Husks The cornstalk stubble left by BT Choppers serves as form of snow fence by preventing the blowing of leaves and husks on windy days. Confetti-like residue stays in place and is less likely to blow. Zone-A Zone-B Note: The spirals and open windows have been removed. Zone A: Knives maintain grasp and control of the stalk. Zone B: Intermeshing knives chop, cut and shear. BT Choppers achieve instant residue-to-soil contact by chopping and shearing cornstalks into small pieces, while simultaneously exposing the pitch for accelerated residue decomposition. JD 600/700 Series 20

22 High Leaf Intake, Butt Shelling, and Unhusked Ears PROBLEM Straight Stripper Plates Factory straight stripper plates are not formed to match the natural shape of the bottom side of the corn ear. During ear separation, the plant leaves engage with these straight stripper plates, causing them to be unnecessarily torn from the stalk. Because factory straight stripper plates do not emulate the rounded butt of the corn ear, they do not allow the ear shank to get close enough to the stalk rolls to grasp the ear shank. This results in the husk staying attached to the ear, sending it and more material into the combine. The Evidence Cornstalk leaves and ear husks are mixed-in with yellow ears during the kill stop examinations. (See photo below on right) The cornstalk leaves and ear husks are mixed in with yellow ears during kill stop examinations. Factory straight stripper plates increase butt shelling. Too much yellow (leaves, husks and stalks) out of the straw chipper is evidence of high trash intake and that the corn head is picking dirty. 21 JD 600/700 Series

23 JD 600/ 700 Series Multi-Zone Beveled Stripper Plates SOLUTION Install Calmer s Multi-Zone Beveled Stripper Plates These multi-zones beveled stripper plates are straight in the front retrieving area to reduce ear wedging and beveled in the stripping area to allow the stalk rolls to engage more shanks, husks and leaves, reducing trash intake by an average of 33%. The beveled edge also emulates the rounded bottom of the corn ear to help reduce butt shelling issues. These beveled stripper plates are hard surfaced for extended life. The Results We installed Calmer s Multi-Zone Beveled Stripper Plates on half of our test head, while the other half remained equipped with factory straight stripper plates. The stripper plate gaps were set the same on both sides of the corn head during testing. We did multiple kill stops at normal ground speeds on a dry afternoon, bagged any loose trash on both sides, weighed it and compared the difference. Here were our findings: On the side of the corn head equipped with Calmer s multi-zone beveled stripper plates, trash was reduced by an average of 33% Harvesting speeds increased significantly Calmer s Multi-Zone Beveled Stripper Plates emulate the rounded bottom of the corn ear. This does a better job of displacing the energy that causes butt shelling. The stripper plates make for smoother feeding, are less row sensitive and great for slopes and curves. Last fall things went smooth with my 600 series rolls and this spring, residue was easy to manage with the planter. Mike Shaw OGDEN, IA Time 1:15 2:00 2:10 2:30 3:00 3:30 4:30 Ounces of Trash with Straight Stripper Ounces of Trash with Beveled Stripper Plates Ounces of Trash Reduced Percentage of Trash Reduced 40% 13% 0% 42% 40% 30% 36% 33% Average Calmer s beveled stripper plates push more kernels toward the cob, reducing butt shelling. JD 600/700 Series 22

24 Profitable Corn Head Adjustments and Modifications Oil bath settings For Variable Speed Feeder Houses, Leave at Factory Settings (outlined below) The 600 series corn head should have the oil bath in underdrive, the large sprocket on the front (driven), and the small sprocket on the rear (driver). Please refer to the following 600 series corn head gear ratios: Chopping Corn Head 24 Driver; 27 Driven Non-Chopping Corn Head 30 Driver; 33 Driven For Fixed Speed Feeder Houses Only The 600 corn head should have the oil bath in overdrive, the large sprocket on the back (driver), and the small sprocket on the front (driven). Please refer to the following 600 corn head gear ratios: Non-Chopping Corn Head - 33 Driver; 30 Driven Chopping Corn Head - 27 Driver; 24 Driven Check lube level in gear boxes See manufacturer s owner s manual for proper lubricant specifications. Calibrating gathering chain speed To calibrate RPMs, all Calmer 600 orders come with a yellow colored paddle to bolt on a center gathering chain lug. Raise the corn head, put combine in park, engage threshing motor to full speed. Count revolutions for 1 minute. Begin calibration with initial gathering chain speed of 55 RPMs. If butt shelling is a problem, slow down the corn head speed until it starts to bulldoze cornstalks, then speed back up until bulldozing stops. To reduce ear toss Stay on the fast sprocket for feeder chain speed when harvesting. Move cross auger back as close as possible to the feeder chain drum. Add half and/or full links to the feeder chain to extend toward the cross auger. This reduces the dead air space between the feeder chain and cross auger flighting. This also reduces the height of the pile of ears between the cross auger and the feeder house, along with reducing back feeding and ear toss. Some older John Deere corn heads use rubber flaps and no reverse flighting. The performance of these older augers is poor. It is recommended that you remove the rubber flaps. If necessary, add reverse flighting to the center of the auger. The short section of reverse flighting can be purchased from John Deere (RH part #H206301, LH part #H206302) and welded on. (See photo below on the right) Setting stripper plates Begin with normal settings of 1 1/8-inch gap at the front and 1 3/16-inch gap at the rear, then adjust accordingly to ensure plates are 1/16-inch wider than the diameter of the 3rd cornstalk node above the brace root. Ensure stripper plate gap is centered over the stalk rolls. Bolt onto center gathering chain lug. Arrow points to where the yellow gathering chain lug should be bolted to the gathering chain. 23 JD 600/700 Series

25 JD 600/ 700 Series Used gathering chain tighteners occasionally lock-up This is caused when the spring vibrates and augers itself into the hole between the bolt and the flat strap. This can be fixed by removing the idler bolt and adding a second washer (enclosed) at the bottom of the pipe spacer, which is identical to the washer at the top of the pipe spacer. Apply anti-seize or lubricant to the bolt threads for future adjustments. Corn head angle is very important! The angle of the corn head should be between degrees for optimum performance in standing corn. The angle should be set to 20 degrees in down/lodged corn. Flattening the angle to 20 degrees in down corn makes gravity less of an enemy. To set the corn head angle, put the combine on a level surface, then lower the corn head until the row unit frame is 2-inches off the ground. Place a magnetic protractor (included with all stalk roll and residue management kit purchases) on the stripper plate and read the angle (See photo below on the right). If the angle is too steep, pull the top of the corn head toward the combine or pushout the bottom with a wedge kit, or a combination of both. Adjust auger to 1 ¾-inches clearance between flighting and tray at the tightest point to reduce ear slicing. Also adjust rearward as far as possible. Sieve settings Marion s recommendations: In Corn: The bottom sieve is not needed. There is no part of the cob or kernel that needs to be rethreshed. Therefore, the bottom sieve should be wide open. This allows the kernels to fall directly into the clean auger. The bottom sieve is now functioning as a wind board and helps direct the air blast to the front of the top sieve where it is needed for cleaning. During corn harvest there should be nothing in the return elevator but the chain and paddle. I would suggest a couple of kill stops to confirm this. The top sieve is now the cleaning sieve and has plenty of capacity to perform this function without losing kernels out the back. I open and close the top sieve as kernel size and moisture change to remove 95% of the cobs from the grain tank. Sieve loss should be less than separator loss. The above information reflects my reasoning and train of thought. Call me on my cell with any questions: (309) Marion Calmer Use a protractor to achieve the correct corn head angle. JD 600/700 Series 24

26 Case-IH 2200/2400 Series and NH 96c, 98c, and 996 Series Corn Heads Follow Calmer s 3-step upgrade process to solve many of your corn head and residue management problems. Install Calmer BT Chopper STEP 1 Stalk Rolls STEP 2 Reliable and effective stalk rolls are critical to a top-performing corn head. Calmer s BT Chopper Stalk Rolls have a redesigned nose cone and a patented open window design in the front to guarantee 100% traction of stalks and superior feeding in both standing and down corn. The 10 razor sharp knives on each roll cut, chop and shear cornstalks into confetti-like pieces for accelerated decomposition. As a result, you ll be able to more effectively manage residue during tillage and planting. Install Calmer Multi-Zone Beveled Stripper Plates STEP 3 The contour of the Calmer Multi-Zone Beveled Stripper Plates emulates the butt of the corn ear, which helps reduce butt shelling while simultaneously reducing trash intake by allowing husks and leaves to pass through the stripper plate gap onto the ground, not into the combine. Install 7-Tooth Drive and 9-Tooth Idler Sprockets and Chrome-Pin Gathering Chains Chrome-Pin Gathering Chains are an available option with every upgrade kit. The chrome-pin design results in a longer-lasting, more durable chain. Calmer s 9-Tooth Idler Sprockets are non-greaseable with replaceable bearings and have a solid-steel design for increased wear life and lower maintenance than OEM idler sprockets. The larger 9-tooth idler sprocket design also improves the gathering chains grabbing ability for easier harvesting in down corn conditions. We recommend running the factory 7-Tooth Drive Sprockets with the 9-tooth idler sprocket combination. Calmer s Over-Sized Plastic Gathering Chain Paddles can be installed on the gathering chain lugs to improve both the gathering and conveying performance of material. BT Chopper Residue OEM Residue Left: BT Choppers explode stalks and expose pith for maximum decomposition and less tire wear. Right: Rotary blades leave stalks in-tact, resulting in slower decomposition and increased wear on tires. 25 Case-IH 2200/2400 & NH 96c/98c/996

27 CIH/NH Series 2 patented open windows per revolution allow stalks to be easily engaged and processed. Hydraulic Adjust Multi-Zone Beveled Stripper Plates for Case-IH 2200/2400 Series Corn Heads Hydraulic Adjust Multi-Zone Beveled Stripper Plates for NH 96c, 98c, and 996 Series Corn Heads 9-Tooth Idler Sprockets Chrome-Pin Gathering Chains 7-Tooth Drive Sprockets We put the Calmer BT Chopper on our Halfway through harvest we purchased a We were so pleased with the performance of the choppers that we put the ones off the 2208 onto the 2212, and hurried to pick-up the extra 4 rows needed from Calmer. These work extremely well! Eldon Hermunslie WAHPTON, ND Case-IH 2200/2400 & NH 96c/98c/996 26

28 Cornstalks Still Standing After Harvest PROBLEM No Feeding Chamber 2 bolt-on blades only make 4 cutting knives Steel Flutes Block Entry NO Entry Window CASH-IH knife roll The Evidence Cantilevered stalk rolls with 4 flutes have too much overlap in the entry area. When rotating at normal speeds, these intermeshing flutes prevent cornstalks from engaging easily with the flutes. This hesitation results in stalks and ears passing below the corn head without being processed. The Results To demonstrate, we put a cornstalk in front of an OEM stalk roll s knife chamber. Because it does not have a revolving window, the cornstalk cannot engage with the flutes and ultimately bends over. (See photo below) Cornstalks CANNOT travel easily into knife chamber. No Stalk Engagement 27 Case-IH 2200/2400 & NH 96c/98c/996

29 CIH/NH Series Calmer s Patented Open Window Creates A Feeding Chamber SOLUTION Install Calmer s Patented BT Chopper Stalk Rolls 10 razor sharp knives process stalks Open Window Patented Open Window During rotation, the shortened flutes are timed to create 2, 4-inch open windows for superior stalk engagement. The Evidence Calmer s patented open window allows the cornstalks to feed easily from the spiral area into the 17 1/2-inch knife chamber, which allows for the entire cornstalk to be processed. This makes for longer stalk roll life and reduces low ear snap and the bulldozing of stalks at the end rows. Because this open window guarantees 100% traction the first time a blade touches the stalk, this ultimately means increased profits for you! The Results To demonstrate, we put a cornstalk in front of the Calmer BT Chopper Stalk Roll. Because of its patented open window, the stalk stays vertical and is easily received and engaged by its 10 razor sharp blades. Cornstalks CAN travel easily into this roll with an open window. Calmer BT Choppers explode stalk stubs for quicker residue decomposition and less tire wear! Case-IH 2200/2400 & NH 96c/98c/996 28

30 Long, Unprocessed Stalks Are Slow to Decompose PROBLEM Non-Agressive Flutes Result in Long Stalks That Limit Residue to Soil Contact Cornstalks did not travel into the knife chamber. Tall stalks left in the field will be slow to decompose. Residue from factory rolls is hard to plant into. Calmer BT Chopper residue is easier to plant into. Knife-to-Knife Stalk Rolls = 92% residue cover on 06/25/2014 Calmer BT Chopper Stalk Rolls = 78% residue cover on 06/25/ Case-IH 2200/2400 & NH 96c/98c/996

31 CIH/NH Series 10 Intermeshing, Razor-Sharp Flutes Cut, Chop and Shear Cornstalks into Confetti for Residue-to-Soil Contact Install Calmer s Patented BT Chopper Stalk Rolls When harvesting, the upper pair of knives on the BT Choppers maintain grasp and control of stalks (Zone A below). This prevents the upper portion of stalks from becoming disengaged and eventually going in the combine. The center pair of knives cut, chop and shear cornstalks into confetti-like residue for accelerated decomposition, eliminating the need for chopping stalks or chopping corn heads. (Zone B below) SOLUTION Never chop stalks again! Cut, Chop and Shearing Area Less Blowing of Leaves and Husks The cornstalk stubble left by BT Choppers serves as form of snow fence by preventing the blowing of leaves and husks on windy days. Confetti-like residue stays in place and is less likely to blow. Zone-A Zone-B Note: The spirals and open windows have been removed. Zone A: Knives maintain grasp and control of the stalk. Zone B: Intermeshing knives chop, cut and shear. BT Choppers achieve instant residue-to-soil contact by chopping and shearing cornstalks into small pieces, while simultaneously exposing the pitch for accelerated residue decomposition. Case-IH 2200/2400 & NH 96c/98c/996 30

32 High Leaf Intake, Ear Jamming In Down Corn PROBLEM Complete Front to Back Bevel Factory stripper plates are beveled all the way from the front to the back, which can result in ear lodging in down corn. The Evidence Factory beveled stripper plates are also beveled in the front retrieving area, preventing the gathering chain lugs from kicking-out lodged ears, which occurs more frequently in down corn situations. (See photo below on the left) Factory beveled edge Factory plates are beveled in the front where they should be straight, which causes ear jamming in down corn. Hairpinning caused by stripper plates and stalk rolls not performing well. 31 Case-IH 2200/2400 & NH 96c/98c/996

33 CIH/NH Series Multi-Zone Beveled Stripper Plates Install Calmer s Multi-Zone Beveled Stripper Plates These multi-zone beveled stripper plates are straight in the front retrieving area to reduce ear wedging and beveled in the stripping area to allow the stalk rolls to engage more shanks, husks and leaves, reducing trash intake by an average of 33%. The beveled edge also emulates the rounded bottom of the corn ear to help reduce butt shelling issues. These beveled stripper plates are hard surfaced for extended life The Results The straight edge design at the front of Calmer s Multi-Zone Beveled Stripper Plates reduces ear wedging by allowing the lugs of the gathering chains to make connection with and remove lodged ears. The lodged ears are then able to fall out of the bottom of the stripper plates. (See photo below on the right) Beveled SOLUTION stripper plates REALLY work good! Bought the head with bad rolls, put Calmer s on and we just love it! Jeff Stahly LAKE PARK, IA Straight in front Calmer s Multi-Zone Beveled Stripper Plates emulate the rounded butt of an ear. This does a better job of displacing the energy that causes butt shelling. Hard surfaced beveled edge More yellow ears and less trash indicates the stalk rolls and stripper plates are performing properly. Calmer s muti-zone beveled stripper plates are closer to the lug which causes them to be sheared, and keeps them from lodging, especially in down corn. Case-IH 2200/2400 & NH 96c/98c/996 32

34 Profitable Corn Head Adjustments and Modifications Oil bath settings: Case-IH 2200 The 2200 corn head should have the oil bath in overdrive, the large sprocket on the back (driver), and the small sprocket on the front (driven). Please refer to the following corn head gear ratios: 2206 and 2212 corn heads should be set to 28 Driver; 22 Driven, low side of gearbox corn heads should be set to 34 Driver; 26 Driven, low side of gearbox. Oil bath settings: Case-IH 2400 The 2400 corn head should have the oil bath in 1 to 1 ratio. Run the feeder house speed wide open. Check lube level in gear boxes See manufacturer s owner s manual for proper lubricant specifications. Calibrating gathering chain speed To calibrate RPMs, all Calmer orders come with an orange colored paddle to bolt on a center gathering chain lug. Raise the corn head, put combine in park, engage threshing motor to full speed. Count revolutions for 60 seconds. Begin calibration with initial gathering chain speed of 55 RPMs. If butt shelling is a problem, slow down the corn head speed until it starts to bulldoze cornstalks, then speed back up until bulldozing stops. To reduce ear toss Stay on the fast sprocket for feeder chain speed when harvesting. Move cross auger back as close as possible to the feeder chain drum. Add half and/or full links to the feeder chain to extend toward the cross auger. This reduces the dead air space between the feeder chain and cross auger flighting. This also reduces the height of the pile of ears between the cross auger and the feeder house, along with reducing back feeding and ear toss. When running on combines with variable speed feeder houses, run as close to wide-open as possible. Bolt onto center gathering chain lug. Arrow points to where the red gathering chain lug should be bolted to the gathering chain. 33 Case-IH 2200/2400 & NH 96c/98c/996

35 CIH/NH Series Setting stripper plates Begin with normal settings of 1 1/8-inch gap at the front and 1 3/16-inch gap at the rear, then adjust accordingly to ensure plates are 1/16-inch wider than the diameter of the 3rd cornstalk node above the brace root. Ensure stripper plate gap is centered over the stalk rolls. Corn head angle is very important! The angle of the corn head should be between degrees for optimum performance in standing corn. The angle should be set to 20 degrees in down/lodged corn. Flattening the angle to 20 degrees in down corn makes gravity less of an enemy. To set the corn head angle, put the combine on a level surface, then lower the corn head until the row unit frame is 2-inches off the ground. Place a magnetic protractor (included with all stalk roll and residue management kit purchases) on the stripper plate and read the angle (See photo below on the right). If the angle is too steep, pull the top of the corn head toward the combine or pushout the bottom with a wedge kit, or a combination of both. Plastic gathering chain paddles attached to the gathering chain lugs will improve gathering and conveying performance in down corn. Adjust auger to 1 ¾-inches clearance between flighting and tray at the tightest point to reduce ear slicing. Also adjust rearward as far as possible. Sieve settings Marion s recommendations: In Corn: The bottom sieve is not needed. There is no part of the cob or kernel that needs to be rethreshed. Therefore, the bottom sieve should be wide open. This allows the kernels to fall directly into the clean auger. The bottom sieve is now functioning as a wind board and helps direct the air blast to the front of the top sieve where it is needed for cleaning. During corn harvest there should be nothing in the return elevator but the chain and paddle. I would suggest a couple of kill stops to confirm this. The top sieve is now the cleaning sieve and has plenty of capacity to perform this function without losing kernels out the back. I open and close the top sieve as kernel size and moisture change to remove 95% of the cobs from the grain tank. Sieve loss should be less than separator loss. Reduce ear toss by moving cross auger back as close as possible to feeder chain drum. Use a protractor to achieve the correct corn head angle. Case-IH 2200/2400 & NH 96c/98c/996 34

36 Geringhoff NorthStar Series Corn Heads Follow Calmer s 2-step upgrade process to solve many of your corn head and reside management problems. STEP 1 Install Calmer BT Chopper Stalk Rolls Reliable and effective stalk rolls are critical to a top-performing corn head. Calmer s BT Chopper Stalk Rolls have a patented open window design in the front to guarantee 100% traction of stalks and superior feeding in both standing and down corn. The 10 razor sharp knives on each roll cut, chop and shear cornstalks into confetti-like pieces for accelerated decomposition. As a result, you ll be able to more effectively manage residue during tillage and planting. STEP 2 Install Calmer Multi-Zone Beveled Stripper Plates The contour of Calmer Multi-Zone Beveled Stripper Plates emulates the butt of the corn ear, which helps reduce butt shelling while simultaneously reducing trash intake by allowing husks and leaves to pass through the stripper plate gap onto the ground, not into the combine. We recommend running a 32-Tooth Crown Gear in the gear case located on the side of corn head to help reduce corn head speed, which will decrease both ear bounce and butt shelling problems. OEM Residue BT Chopper Residue Side-by-side comparison just 7 months after harvest shows superior residue decomposition when using Calmer BT Chopper stalk rolls compared to OEM stalk rolls. 35 Geringhoff NorthStar Corn Heads

37 Geringhoff NorthStar Never chop stalks again! 2 patented open windows per revolution allow stalks to be easily engaged and processed. Hydraulic Adjust Multi-Zone Beveled Stripper Plates I can go faster through the field and the Choppers really do a job on the stalks. Planting is easier since the stalks have decomposed. David Wilson FRANKLIN, IL Chews it up, especially for spring field cultivator! Kurt Lowenbe HENDRICK, IA Geringhoff NorthStar Corn Heads 36

38 Case-IH 3000 Series and NH 98D (with nose bearing) Series Corn Heads Follow Calmer s 3-step upgrade process to solve many of your corn head and reside management problems. STEP 1 STEP 2 STEP 3 Install Calmer BT Chopper Stalk Rolls Reliable and effective stalk rolls are critical to a top-performing corn head. Calmer s BT Chopper Stalk Rolls have a patented open window design in the front to guarantee 100% traction of stalks and superior feeding in both standing and down corn. The 8 razor sharp knives on each roll cut, chop and shear cornstalks into more management pieces for accelerated decomposition. As a result, you ll be able to more effectively manage residue during tillage and planting. Install Calmer Multi-Zone Beveled Stripper Plates (Required) The contour of Calmer Multi-Zone Beveled Stripper Plates emulates the butt of corn ear, which helps reduce butt shelling while simultaneously reducing trash intake by allowing husks and leaves to pass through the stripper plate gap onto the ground, not into the combine. Install 7-Tooth Drive and 9-Tooth Idler Sprockets and Chrome-Pin Gathering Chains Chrome-Pin Gathering Chains are an available option with every upgrade kit. The chrome-pin design results in a longer-lasting, more durable chain. Calmer s 9-Tooth Idler Sprockets are non-greaseable with replaceable bearings and have a solid-steel design for increased wear life and lower maintenance than OEM idler sprockets. The larger 9-tooth idler sprocket design also improves the gathering chains grabbing ability for easier harvesting in down corn conditions. We recommend running the factory 7-Tooth Drive Sprockets with the 9-tooth idler sprocket combination. Calmer s Over-Sized Plastic Gathering Chain Paddles can be installed on the gathering chain lugs to improve both the gathering and conveying performance of material. BT Chopper Residue OEM Residue Left: BT Choppers explode stalks and expose pith for maximum decomposition and less tire wear. Right: Rotary blades leave stalks in-tact, resulting in slower decomposition and increased wear on tires. 37 Case-IH 3200/3400 & NH 98D Series

39 CIH 3000/ NH 98D Never chop stalks again! 2 patented open windows per revolution allow stalks to be easily engaged and processed. Multi-Zone Beveled Stripper Plates (Required with all Case 3000 Upgrade Kits) 9-Tooth Idler Sprockets Chrome-Pin Gathering Chains 7-Tooth Drive Sprockets After harvest, corn ground was disk chiseled. We had no problems. In the spring, we hit with a cultivator and drilled soybeans no plugging. Spring went well. Jeff Dansby FOWLERVILLE, MI I just want to say the Calmer stalk rolls are the best investment I ve ever made. Larry Groves MAROA, IL Case-IH 3200/3400 & NH 98D Series 38

40 AGCO Corn Heads Follow Calmer s 2-step upgrade process to solve many of your corn head and reside management problems. STEP 1 Install Calmer BT Chopper Stalk Rolls Reliable and effective stalk rolls are critical to a top-performing corn head. Calmer s BT Chopper Stalk Rolls have a redesigned nose cone and a patented open window design in front to guarantee 100% traction of stalks and superior feeding in both standing and down corn. The 8 razor sharp knives on each roll cut, chop and shear cornstalks into more management pieces for accelerated decomposition. As a result, you ll be able to more effectively manage residue during tillage and planting. STEP 2 Install Calmer Multi-Zone Beveled Stripper Plates The contour of Calmer Multi-Zone Beveled Stripper Plates emulates the butt of the corn ear, which helps reduce butt shelling while simultaneously reducing trash intake by allowing husks and leaves to pass through the stripper plate gap onto the ground, not into the combine. OEM Residue BT Chopper Residue Side-by-side comparison just 7 months after harvest shows superior residue decomposition when using Calmer BT Chopper stalk rolls compared to OEM stalk rolls. 39 Gleaner Hugger & Massey Ferguson 3000 Series Corn Heads

41 AGCO Never chop stalks again! 2 patented open windows per revolution allow stalks to be easily engaged and processed. Manual Adjust Multi-Zone Beveled Stripper Plates Electric Adjust Multi-Zone Beveled Stripper Plates (Long-Tab or Short-Tab) Verify Electric Stripper Plate Tabs For Gleaner Hugger and MF 3000 Series Corn Heads with electric stripper plates, It is necessary to verify if it is equipped with the long-tab or short-tab electric stripper plates design. This can be determined by measuring the distance between the outside of each stripper plate as shown below. Electric stripper plates with the long-tab design should measure approx. 8 7/8 across (shown left). Electric stripper plates with the short-tab design should measure approx. 8 1/8 across (shown right). Long-Tab Design = Approx. 8 7/8 Short-Tab Design = Approx. 8 1/8 Gleaner Hugger & Massey Ferguson 3000 Series Corn Heads 40

42 Maximize your Profit Potential with Calmer s Custom Built Corn Heads! As the maker of the world s first single-chain, narrow row independent corn heads for 12- and 15-inch rows, along with building the world s largest corn heads, we ve spent decades researching and developing patented technologies that give Calmer Corn Heads unrivaled capabilities. Available in any number of rows and row width, our corn heads are manufactured to meet your operation s harvesting needs! Advantages of a Calmer Corn Head Faster harvesting speeds Less trash intake in both standing Superior stalk chop and down corn Less butt shelling Increased gathering chain life Less moving parts Warmer soils Less weight Drier soils Lower maintenance Less horsepower requirements Less grain loss Less fuel needed More bu/ac harvested per day Calmer 8-row, 30-inch Corn Head with Deluxe Upgrade Kit 41

43 Calmer Corn Heads Superior by Design By design, Calmer Corn Heads help maximize your profit potential by enabling you to harvest faster and more effectively than ever before. Here s how: Lightweight Multi-Zone Beveled Stripper Plates BT Chopper Stalk Rolls High-Profile, Shorter Snouts Strategically Realigned 6-Tooth Drive Sprocket Single Chain Design w/ Polyethylene Ear Guide Our patented single-chain design in combination with our low-profile, super-short poly hoods and dividers result in one of the lightest row units in the industry. The unique design of our stripper plates helps reduce ear wedging and butt shelling issues. The stripper plate s beveled design also allows our BT Chopper Stalk Rolls to engage more corn leaves, shanks and husks in order to reduce trash intake and minimize horsepower requirements. The plates elongated design also allows for more efficient harvesting of low hanging ears in down corn. Calmer BT Chopper Stalk Rolls chop, cut and shear cornstalks into confetti-like residue for unrivaled residue management capabilities. Among the shortest on the market, our high-profile snouts make it easy to maneuver through narrow rows and around tight contoured areas. Calmer Corn Heads are realigned to allow superior material flow from the tray to the feeder house, reducing ear toss and allowing for maximum flow in high-yielding and high-speed harvest conditions. The Calmer 6-Tooth Drive Sprockets slow down gathering chains by 25%, reducing trash intake by as much as 60%. Calmer s UHMW (Ultra High Molecular Weight) polyethylene ear guide forms a retaining wall to maintain engagement of the ears with the enlarged hardened steel gathering chain paddles. By utilizing Calmer s single chain system, the second chain, chain guide, drive sprocket, drive shaft, idler block, idler sprocket and chain tension spring are eliminated, significantly reducing weight and maintenance. Stainless steel back walls, trays and auger strippers are standard features on all Calmer Corn Heads. 42

44 Standard Features 12, 15, 20, 22 and 30 row spacing Any color poly deck covers, dividers and wear points to match your combine Calmer BT Chopper Stalk Rolls Stainless steel back wall, tray, and auger stripper Single- or dual-chain design Calmer s patented 6-tooth trash-reducing drive sprockets for superior stalk ejection Outer row strippers offset 1/4-inch for reducing ear loss over the end divider Calmer realignment package for ear toss reduction and maximum horizontal flow rates Cross auger with 18-inch diameter and 26-inch pitch Cross auger adjusted with 1 3/4-inch clearance for reduced ear slicing and cracked kernels John Deere gathering chain tighteners High-performance gathering chain with tall 2.25 x 2.5-inch nylon paddles Calmer Multi-Zone Beveled Stripper Plates for unrivaled husking and leaf ejection Oil bath with 80H heavy chain and 1 1/4-inch heavy duty driveline Telescoping PTO shafts Flashers One year parts/labor warranty Calmer 24-row, 15-inch corn head. Calmer 18-row, 20-inch corn head. Additional Options Hydraulic stripper plates Stubble lights Automatic header height control Row Sense (Auto Guidance) Calmer 12-row, 30-inch corn head. All Calmer Corn Heads come equipped with Calmer s patented BT Chopper Stalk Rolls and Deluxe Residue Management Upgrade Kit. 43

45 Testimonials Don t just take our word for it. Here s what people from around the county are saying about Calmer Products. To view more testimonials or submit your own, go to CalmerCornHeads.com/ Testimonials. It s all about the size of the residue. The BIGGER the particle, the SLOWER it s going to degrade. Dr. Fred Below PROFESSOR OF PLANT PHYSIOLOGY UNIVERSITY OF ILLINOIS We plant wheat into cornstalks and we only disc 1 time. We can t believe how the chopper grinds-up the stalks. The ride is a lot faster now. Larry Hocking MOUNT CARMEL, IL Ran last fall. Perfect for no-tilling sunflowers the following year. There was bare soil and warmth and dryness. Howard Sias CHELSEA, MI I had no problem planting into the Calmer residue this spring. There was no plugging. It was smooth sailing. Alan Overbeck LIBERTY, IN My field is unbelievable. Why are guys spending so much on chopping heads? I did not need a mower or anything ahead of my chisel plow. Ed Blodgett LIMA, NY Bought the rolls and they are unreal. There is really nothing like these rolls it was night and day difference. Gail Radke PARKSTON, SD The stalk rolls are fantastic! What they did for us in the fall was really, really evident in the spring tillage. The residue was reduced considerably. Dan Labertson MARTELLE, IA In my humble opinion, Marion Calmer s technology has changed the way corn will be grown worldwide for the rest of time. Paul Harvey ABC RADIO NETWORK BROADCASTER 44

46 Calmer Trade Show Schedule Calmer Corn Heads does a great job at staying busy throughout the year. We hope you ll stop by and see us at one of the following trade shows near you! Nov 27-29, 2018 Peoria Farm Show Peoria, IL Dec 4-6, 2018 NE Power Farm Show Lincoln, NE Dec 13, 2018 Calmer Winter Seminar Lynn Center, IL Jan 3-4, 2019 SouthWest Agricultural Ridgetown, ON, Canada Conference Jan 8-11, 2019 National No-Till Conferece Indianapolis, IN Jan 15-17, 2019 Fort Wayne Farm Show Fort Wayne, IN Jan 20-22, 2019 Quad Cities Farm Show Rock Island, IL Jan 23-25, 2019 Sioux Falls Farm Show Sioux Falls, SD Jan 29-31, 2019 Iowa Power Farm Show Des Moines, IA Jan 30 - Feb 1, 2019 Southern Farm Show Raliegh, NC Jan 31 - Feb 2, 2019 US Custom Harvesters Amarillo, TX Feb 7, 2019 Calmer Winter Seminar Lynn Center, IL Feb 13-16, 2019 National Farm Machinery Show Louisville, KY Feb 28 - Mar 2, 2019 Commodity Classic Orlando, FL 45

47 The Economics At Calmer Corn Heads, we believe if you re going to spend your hard-earned money on products for your farming operation, there must be proven track record and a return on your investment (ROI). As a farmer invented, farmer tested and farmer proven solution to both corn head and residue management problems, we are confident this kit will not only perform to the highest of standards, but will also make you money in the process. Complete the ROI plan below to get an estimate on the economic return of running Calmer BT Chopper Stalk Rolls and Upgrade Kits bu/ac increase when growing continuous corn 1 = $20.10 x Acres = $ *Corn Value at $3.35 bu 2. 2 bu/ac increase in no-till soybeans in a corn-soybean rotation 2 = $18.80 x Acres = $ *Soybeans valued at $9.40 bu 3. Eliminate chopping cornstalks = $11.25 x Acres = $ Chopping cornstalks valued at $11.25 per acre 3 4. Add totals from 1, 2, and 3 together = $ Total potential savings per year *Corn and soybean values based on market year average prices for 2018, published by USDA in Agricultural Projections to Residue and Agronomic Management to Lessen the Continuous Corn Yield Penalty, Alison Vogel, Tryston Beyrer, Dr. Fred Below Department of Crop Sciences, University of Illinois at Urbana-Champaign 2 Calmer Agronomic Research Center 3 Plastina, A. and Johanns, A. (2018) Iowa Farm Custom Rate Survey. [online] Ames, Iowa: Iowa State University Extension and Outreach, p.1. Available at: [Accessed 5 Jun. 2018]. Legal Notice Calmer Corn Heads may, at any time and without prior notice, modify the content and operation of its website or this brochure, remove or modify the specific patents and/or patent list demonstrated in this brochure or on its web site A partial list of United States (US) patents that Calmer Corn Heads either owns or licenses for its products includes: 5,704,202; D494,605; 7,104,038; 7,373,767; 7,886,510; 8,171,708; 8,220,237; 8,464,505; 8,857,139 and 8,863,487. Other US and foreign patents are pending on the Company s products and technologies. All product names, whether or not appearing in large print or with the trademark symbol, are trademarks of Calmer Corn Heads, its affiliates, related companies or its licensors or joint venture partners, unless otherwise noted. All other trademarks, service marks, and logos (hereinafter Marks ) used in this brochure are the Marks of their respective owners. The following is a partial list of registered trademarks: Calmer, the Calmer C logo, BT Chopper, Calmer BT Chopper and Calmer BT Crusher. Other Calmer Corn Heads logos are the exclusive trademark of Calmer Corn Heads. Nothing contained herein shall be construed as conferring any license or right under any patent, trademark or copyright of Calmer Corn Heads, Inc. or any third party. Calmer Corn Heads actively and aggressively enforces its intellectual property rights to the fullest extent of the law. All images and text are the exclusive property of Calmer Corn Heads, Inc. Copyright The foregoing economic worksheet is based upon data from agronomic educational institutions or other institutions. Calmer Corn Heads use of this data is reflected in the worksheet, but other data or factors may be used to produce differing results and, also, results may vary based upon farmer s actions, field conditions and geography. Calmer Corn Heads makes no warranties, guarantees or promises as to the data or the analysis presented in the worksheet, or recommendations based thereon. 46

48 Presorted Standard US Postage PAID Permit 59 Rock Island, IL Calmer Corn Heads P.O. Box 9 Alpha, IL The information in this catalog reflects my expertise on the benefits of my residue management improvement system and how the Calmer BT Chopper is the most capable stalk roll system in the industry. These patented parts are Farmer Invented, Farmer Tested, and Farmer Proven to get you real results, while making you money in the process. Marion Calmer CEO Calmer Corn Heads, Inc. President Calmer Ag Research Center Owner/Operator Calmer Farms Farmer Invented. Farmer Tested. Farmer Proven. CalmerCornHeads.com P: (309) info@calmercornheads.com Printed November 2018